Arctic Cat PROWLER HDX 2015 Service Manual
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Arctic Cat PROWLER HDX 2015 Service Manual

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S E R V I C E M A N U A L
S E R V I C E M A N U A L
S E R V I C E M A N U A L
PROWLER HDX
www.arcticcat.com

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Summary of Contents for Arctic Cat PROWLER HDX 2015

  • Page 1 S E R V I C E M A N U A L S E R V I C E M A N U A L S E R V I C E M A N U A L PROWLER HDX www.arcticcat.com...
  • Page 2 This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed.

  • Page 4: Table Of Contents

    Table of Contents General Information ............2 Gas Tank ................. 121 General Specifications............2 Gas/Vent Hoses .............. 123 Torque Specifications ............3 Oil Filter/Oil Pump ............123 Torque Conversions (ft-lb/N-m)..........5 Liquid Cooling System ............ 124 Gasoline - Oil - Lubricant.............5 Radiator................124 Genuine Parts..............6 Thermostat ..............

  • Page 5: General Information

    1.9 L (2.0 U.S. qt) - Change Piston Pin Outside Diameter (min) 22.99 mm Gasoline (recommended) 87 Octane Regular Unleaded VALVES AND GUIDES (500) Engine Oil (recommended) Arctic Cat ACX All Weather Valve Face Diameter (intake) 35.0 mm Synthetic (exhaust) 30.5 mm Front Differential/Rear Drive Lubricant...

  • Page 6: Torque Specifications

    DRIVE TRAIN COMPONENTS CRANKSHAFT (500) Torque Connecting Rod (small end) (max) 20.021 mm Part Part Bolted To ft-lb N-m Connecting Rod (big end side-to-side) 0.7 mm (max) Rear Differential/Gear Case Frame Connecting Rod (big end width) 21.95-22.00 mm Drive Coupler (Front) Front Drive Flange Connecting Rod (small end deflection) 3.0 mm...
  • Page 7 SUSPENSION COMPONENTS (Front) ENGINE/TRANSMISSION (700) Torque Clutch Shoe** Crankshaft 221 300 Part Part Bolted To ft-lb Clutch Cover/Housing Assem- Crankcase A-Arm Frame Crankcase Half (6 mm) Crankcase Half Knuckle Ball Joint Crankcase Half (8 mm) Crankcase Half Shock Absorber Frame/Upper A-Arm Cylinder Head (Cap Screw) Crankcase Shock Absorber...

  • Page 8: Torque Conversions (Ft-Lb/N-M)

    36.7 70.7 104.7 tor-based oils. 38.1 72.1 106.1 The recommended oil to use is Arctic Cat ACX All 39.4 73.4 107.4 Weather synthetic engine oil, which has been specifi- 40.8 74.8 108.8 cally formulated for use in this Arctic Cat engine.

  • Page 9: Genuine Parts

    Preparation After When replacement of parts is necessary, use only genuine Arctic Cat parts. They are precision-made to ensure high Storage quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description.

  • Page 10: Periodic Maintenance

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change and strainer inspection interval can be increased to every 1,000 miles or every year.

  • Page 11: Lubrication Points

     NOTE: Foam Filter Cleaner and Foam Filter Oil are available from Arctic Cat. 5. Squeeze the element by pressing it between the HDX237A palms of both hands to remove excess solvent. Do no 2.

  • Page 12: Valve/Tappet Clearance

    CHECKING AND CLEANING DRAINS CC007D Valve Adjuster Procedure HDX089A A. Place the Valve Clearance Adjuster onto the jam 1. Inspect the “duck-bill” drain beneath the main hous- nut securing the tappet adjuster screw; then rotate ing for debris and for proper sealing. the valve adjuster dial clockwise until the end is 2.

  • Page 13: Spark Plug

    NOTE: The seat, seat back, and seat base must be removed for this procedure. 1. Remove the high tension lead from the spark plug. 2. Using compressed air, blow any debris from around the spark plug. ! WARNING Always wear safety glasses when using compressed air.

  • Page 14: Engine/Transmission Oil - Filter

    PR498 PR078A 3. Using the Oil Filter Wrench and a ratchet handle (or a socket or box-end wrench), remove the old oil filter. NOTE: Clean up any excess oil after removing the fil- ter. 4. Apply oil to a new filter O-ring and check to make sure it is positioned correctly;...

  • Page 15: Front Differential - Rear Drive Lubricant

    6. Start the engine (while the vehicle is outside on level 2. Remove each fill plug. ground) and allow it to idle for a few minutes. 3. Drain the lubricant into a drain pan by removing in turn 7. Turn the engine off and wait approximately one minute; the drain plug from each.

  • Page 16: Headlight/Taillight-Brakelight

    4. Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights. Headlight/Taillight- Brakelight 5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM. 6. Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm HEADLIGHT (2 in.) below the horizontal mark on the aiming surface.

  • Page 17: Hydraulic Brake System

    CHECKING/BLEEDING The hydraulic brake system has been filled and bled at the factory. To check and/or bleed a hydraulic brake sys- tem, use the following procedure. 1. With the master cylinder in a level position, check the fluid level in the reservoir. If the level in the res- ervoir is not above the MIN, add DOT 4 brake fluid.
  • Page 18 CHECKING/REPLACING PADS REAR 700 The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thick- ness of each of the brake pads as follows.

  • Page 19: Burnishing Brake Pads

    CF363 PR377B 3. Remove the nut securing the movable drive face; 5. Install the wheel. Tighten in 20 ft-lb increments to 40 then remove the face. Account for the spacer. ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).  NOTE: Keep the drive face plate in contact with the 6.
  • Page 20 GZ076 CF366 CAUTION Make sure the movable drive face plate is fully engaged onto the splines of the clutch shaft before tightening the nut or false torque readings may occur. This will cause the assem- bly to loosen damaging the shaft and clutch face plate. GZ085 INSTALLING 1.

  • Page 21: Steering/Frame/Controls

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and full- right capability. C. Steering sector mounting bolts tight. PR760A D. Ball joints not worn, cracked, or damaged. 4.
  • Page 22 PR765A PR776A 7. Remove the steering shaft housing and shaft from the NOTE: Alignment need only be approximate as steering support and intermediate shaft; then remove final alignment is not possible until the EPS is the intermediate shaft from the EPS input shaft. engaged with the coupler.

  • Page 23: Tie Rods

    PR764B PR780 9. Install the cap screw in the intermediate shaft coupler 4. Using an appropriate crow-foot and backing wrench, and tighten to 31 ft-lb; then tighten the cap screw remove the tie rod assembly. (from step 6) to 11 ft-lb. NOTE: Tie rods come as a complete assembly.

  • Page 24: Steering Assembly

    NOTE: Always attach the crow-foot to the torque wrench with the open end 90° to the torque wrench handle to ensure accurate torque application. PR301 3. Remove the EPS cradle bracket; then remove the cap screws securing the steering rack assembly to the rack bracket and remove from the left side.

  • Page 25: Steering Wheel

    NOTE: If the hole in the steering shaft does not align with the slots in the castle nut, tighten the nut slightly until the next slot aligns with the hole. PR773A 3. Place the tie rod ends into the knuckles and secure with the castle nuts (coated with red Loctite #271).

  • Page 26: Intermediate Steering Shaft Assembly

    NOTE: Any time steering components are disas- sembled, all connecting components should be Intermediate Steering marked for proper alignment during assembling. Shaft Assembly INSPECTING 1. Inspect the steering wheel shaft for excessive wear. AT THIS POINT 2. Check for worn splines, cracks, or damaged threads. Before beginning this procedure, the upper steering shaft 3.

  • Page 27: Steering Knuckles

    6. Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle. 7. Remove the two cap screws securing the ball joints in the knuckle. PR764B 4. Install the cap screw in the intermediate shaft coupler and tighten to 31 ft-lb;...
  • Page 28 NOTE: During assembling, new cotter pins should be installed. 4. Apply a small amount of grease to the hub splines. PR292A PR290A 5. Install the hub assembly onto the splines of the shaft. PR289 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws.

  • Page 29: Accelerator Pedal

    PR260 PR709 NOTE: If the hole in the axle shaft does not align with the slots in the castle nut, tighten the nut until the hole and slots align. 8. Secure the brake caliper to the knuckle with the two new “patch-lock”...

  • Page 30: Shift Cable

    HDX166A HDX168A INSTALLING 1. Install the shift axle supports onto the shift lever; then secure the axle supports to the frame with four cap screws and tighten to 48 in.-lb. HDX178A 3. Tilt the cargo box back and remove the E-clip from the shift arm on the transmission;...

  • Page 31: Lcd Gauge/Indicator Lights

    HDX132A PR762A 3. Remove the six screws securing the dash panel to the INSTALLING frame; then remove the shifter handle and shift lever boot. 1. Route the cable into position making sure there are no kinks or sharp bends. 4. Slide the dash panel to the rear sufficiently to access the components.

  • Page 32: Checking/Adjusting Front Wheel Alignment

    10. Install the steering wheel boot support. PR087A To adjust the wheel alignment, use the following proce- PR762A dure. 11. Install the steering boot onto the boot support. 1. Center the steering wheel; then using an open-end 12. Install the steering wheel; then with a drop of red wrench to hold the tie rod ends, loosen the right-side Loctite #271 on the threads of the steering shaft, and left-side jam nuts.

  • Page 33: Front Bumper Assembly

    PR086 PR328A 2. Loosen but do not remove the four cap screws and flange nuts securing the hood hinge to the frame; Front Bumper Assembly then lower the hood. REMOVING Remove four cap screws and nuts. Account for four lock washers and eight flat washers.

  • Page 34: Fenders

    3. Connect the four headlight connectors; then secure the wires with two new nylon ties. HDX132A 4. While pulling forward on the upper-rear of the floor, lift the rear part of the floor above the seat locating PR332B stud. Fenders REMOVING Remove three torx-head screws securing each fender to the frame.

  • Page 35: Dashboard

    2. Secure the floor with the cap screws and self-tap- pings screws. Belly Panel 3. Install the center floorboard; then install the seat base, seat back, and seat. REMOVING Dashboard 1. Remove the body screws securing the belly panel to the underside of the frame.

  • Page 36: Cargo Box

    INSTALLING Cargo Box 1. With the help of an assistant or an adequate lift, set the cargo box into position on the frame; then posi- tion the two upper pivot housings between the cargo box and frame. Lightly grease the pivot housings. REMOVING 2.

  • Page 37: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Steering shaft binding 2. Lubricate/replace steering shaft 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 38: Engine/Transmission

    Spanner Wrench 0444-240 Surface Plate 0644-016  NOTE: Arctic Cat recommends the use of new gas- V Blocks 0644-535 kets, lock nuts, and seals and lubricating all internal NOTE: Special tools are available from the Arctic components when servicing the engine/ transmis- sion.

  • Page 39: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace guides 3. Valves mistimed 3. Retime engine 4. Piston rings worn - broken 4.
  • Page 40 Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive - driven bevel gears damaged - worn 1. Replace gears 2. Backlash excessive 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 41: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service/replace right- HDX138A side cover oil seals, front output joint oil seal, rear out- 6.
  • Page 42 8. Loosen the clamp securing the throttle body to the intake manifold boot; then remove the throttle body and set aside. 9. From the left side, disconnect the ECT sensor con- nector, speed sensor connector, and spark plug cap. HDX251 ...
  • Page 43 15. Remove the two exhaust springs at the muffler; then remove the exhaust pipe. Account for a grafoil seal in the cylinder head and a grafoil seal at the muffler. HDX147A 13. Remove the forward heat shield from the exhaust pipe;...

  • Page 44: Servicing Engine (500)

    Servicing Engine (500) appropriate wrench, rotate the crankshaft to top- dead-center of the compression stroke. NOTE: Arctic Cat recommends the use of new Top-Side Components ............41 gaskets, lock nuts, and seals and lubricating all Removing Top-Side Components ........41 internal components when servicing the engine/ Servicing Top-Side Components........
  • Page 45 2. Remove the cylinder head cover cap screws. Note the rubber washers on the four top-side cap screws; remove the cylinder head cover. Note the orientation of the cylinder head plug and remove it. Note the location of the two alignment pins. FI608 4.
  • Page 46 MD1131 FI616 6. Noting the timing marks for installing purposes, drop the sprocket off the camshaft. While holding the cam chain, slide the sprocket and camshaft out of the cyl- inder head. Account for an alignment pin. NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase.
  • Page 47 CD211 FI622A 9. Remove the cylinder head from the cylinder, remove 12. Lift the cylinder off the crankcase taking care not to the gasket, and account for two alignment pins. allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. FI623A FI624A AT THIS POINT...

  • Page 48: Servicing Top-Side Components

    CAUTION Do not remove an excessive amount of the sealing sur- face or damage to the camshaft will result. Always check camshaft clearance when resurfacing the cylin- der head cover. MD1219 NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install a con- necting rod holder.
  • Page 49 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- nents be taken to a qualified machine shop for servicing. CAUTION CC132D If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 50 2. Inspect the piston for seizure marks or scuffing. If piston is scored or galled, replace it with a new one. 3. Inspect the perimeter of each piston for signs of “blowby” indicated by dark discoloration. “Blowby” is caused by worn piston rings, excessive carbon in ring grooves, or an out-of-round cylinder.
  • Page 51 Installing Piston Rings Cleaning/Inspecting Cylinder Head CAUTION 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the The cylinder head studs must be removed for this pro- expander making sure the expander ends do not cedure.
  • Page 52 NOTE: To produce the proper 60° cross-hatch 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, pattern, use a low RPM drill (600 RPM) at the rate move the cylinder in a figure eight motion. Inspect of 30 strokes per minute.

  • Page 53: Installing Top-Side Components

    ATV1013A CF060A 2. The lobe heights must be greater than minimum 2. If damaged, the camshaft must be replaced. specifications. Inspecting Camshaft Bearing Installing Top-Side Journal Components 1. Inspect the bearing journal for scoring, seizure marks, or pitting. A. Piston 2.
  • Page 54 C. Cylinder Head/Camshaft D. Cylinder Head Cover/Rocker Arms NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.
  • Page 55 10. With the timing inspection plug removed and the cam chain held tight, rotate the crankshaft until the piston is at top-dead-center. 11. While holding the cam chain to the front, install the rear cam chain tensioner guide into the cylinder head. Install the pivot cap screw and washer.
  • Page 56 16. Place the tab washer onto the sprocket making sure it 19. Rotate the crankshaft until the first cap screw (from covers the pin in the alignment hole. step 17) securing the sprocket to the camshaft can be addressed; then tighten to 10 ft-lb. Bend the tab to secure the cap screw.

  • Page 57: Left-Side Components

    28. Place the two tappet covers with O-rings into posi- tion; then install and tighten the cap screws to 8.5 ft- FI538 2. Remove the water pump housing assembly noting the location of the longer cap screw. Account for a gasket and two alignment pins.
  • Page 58 4. Remove the water pump drive gear; then remove the 8. Using the Magneto Rotor Remover Set, break the speed sensor housing assembly. Account for two rotor/flywheel loose from the crankshaft; then alignment pins, a gasket, and two seal washers. remove the puller and crankshaft protector and remove the rotor/flywheel.

  • Page 59: Servicing Left-Side Components

    Servicing Left-Side Components INSPECTING STARTER CLUTCH/ GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clock- wise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. FI559 If it moves or locks up both ways, the starter clutch 12.
  • Page 60 FI570 FI583 2. Thoroughly clean the rotor/flywheel; then install the 2. Thoroughly clean the gear hub; then apply a drop of new clutch and secure with the cap screws after green Loctite #620 to the bearing outer race and applying a drop of red Loctite #271 to the threads. press into the gear hub until even with the lower Tighten to 26 ft-lb using a crisscross pattern.

  • Page 61: Installing Left-Side Components

    REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sen- sor, and one cap screw from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor.
  • Page 62 MD1122 FI555A 2. Install the starter motor and tighten the two cap 7. Install the starter clutch gear onto the crankshaft; screws to 10 ft-lb. then install the rotor/flywheel key in the crankshaft. 3. Install the shift detent cam making sure the washer is installed.

  • Page 63: Right-Side Components

    13. Connect the coolant hoses to the water pump and secure with the hose clamps. Tighten securely. Right-Side Components AT THIS POINT  To service center crankcase components only, proceed to Removing Right-Side Components. NOTE: For efficiency, it is preferable to remove FI547 and disassemble only those components which 11.
  • Page 64 KC142A MD1036 3. Mark the movable drive face and the fixed drive face 5. Using a 6 mm cap screw threaded into the fixed for installing purposes; then remove the nut holding driven face, spread the driven pulley by turning the the movable drive face onto the crankshaft.
  • Page 65 8. Using an impact screwdriver, remove the three Phil- lips-head cap screws holding the air intake plate. Remove the air intake plate. MD1286 12. Remove the left-hand threaded nut holding the cen- trifugal clutch assembly. MD1092 CAUTION 9. Remove the cap screws holding the clutch cover onto Care must be taken when removing the nut;...
  • Page 66 NOTE: Always use a new snap ring when install- ing the oil pump driven gear. 17. Remove oil pump driven gear. Account for the drive pin and thrust washer. FI630 14. Remove the oil pump drive gear cap screw. MD1020 AT THIS POINT ...

  • Page 67: Servicing Right-Side Components

    INSPECTING CENTRIFUGAL CLUTCH HOUSING 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE 1. Place the one-way clutch onto the clutch shoe assembly with the green dot or the word “OUTSIDE”...

  • Page 68: Installing Right-Side Components

    KC332A MD1208 INSPECTING OIL PUMP 3. Place two alignment pins and the oil pump into posi- tion on the crankcase and secure with the Phillips- 1. Inspect the pump for damage. head screws coated with red Loctite #271. Tighten to 8 ft-lb.
  • Page 69 8. Install the one-way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase. MD1019 5. Install the cam chain. NOTE: Keep tension on the cam chain to avoid MD1286 damaging the crankcase boss. B.
  • Page 70 MD1342 KC137 12. Place the driven pulley assembly into position and NOTE: The arrows on the V-belt should point in secure with the nut (threads coated with red Loctite direction of engine rotation. #271). Tighten to 147 ft-lb. 15. Making sure the movable drive face rollers are in position, pinch the V-belt together near its center and slide the spacer and movable drive face onto the shaft.

  • Page 71: Center Crankcase Components

    Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining purposes. KC141 NOTE: At this point, the cap screw can be removed from the driven pulley face. 17.

  • Page 72: Disassembling Crankcase Half

    FI659A MD1313 Disassembling Crankcase Half NOTE: To aid in installing, it is recommended that the assemblies be kept together and in order. NOTE: For steps 1-6, refer to illustration FI639A. FI661A 2. Remove the reverse idler assembly (B). Account for and note the location of the inner bushing (1), idler shaft (2), and outer washer (3).

  • Page 73: Servicing Center Crankcase Components

    FI653A MD1024 4. Remove the gear shift shaft (F) noting the inner and 7. Using Crankcase Separator/Crankshaft Remover outer washers. with the appropriate crankshaft protector, remove the crankshaft. FI650A MD1330 5. Remove the countershaft assembly (E) along with the shift fork assembly. CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary.
  • Page 74 Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft.

  • Page 75: Crankshaft Assembly

    NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be fol- lowed and the above “Tooth Contact/Shim Correc- tion” chart must be consulted. CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the cor- recting backlash/correcting tooth contact procedures until they are both within tolerance values.
  • Page 76 H1-006 FI665 2. Acceptable width range must be within specifica- 3. Remove the low driven gear washer; then remove the tions. low driven gear along with the bearing and bushing. COUNTERSHAFT CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces.
  • Page 77 FI669 FI671A 5. Remove the circlip securing the high driven gear; then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer. FI670 2. Install the high/low shift dog (6) on the countershaft and secure with snap-ring (7);...

  • Page 78: Assembling Crankcase Half

    FI666 FI662 4. Place the reverse driven bushing (13) onto the shaft; NOTE: The countershaft assembly is now ready then install the bearing (14), gear (15), and splined to be installed. washer (16). Secure with a snap-ring. Assembling Crankcase Half NOTE: For ease of assembly, install components on the right-side crankcase half.
  • Page 79 MD1333 FI658 3. Apply a liberal amount of oil to the crankshaft bear- 6. Align the shift cam fork slots with the shift fork shaft ing. Using a propane torch, heat the bearing until the locating boss and with a washer on each end, install oil begins to smoke;...
  • Page 80 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase. FI645 11. Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses;...

  • Page 81: Joining Crankcase Halves

    Joining Crankcase Halves 1. Verify that the two alignment pins (A) are in place and that both case halves are clean and grease free. Apply Loctite #5900 or suitable substitute sealant to the mating surfaces. Place the right-side half onto the left-side half.

  • Page 82: Servicing Engine (700)

    Servicing Engine (700) Top-Side Components ..........79 Removing Top-Side Components ....... 79 Servicing Top-Side Components ........ 82 Installing Top-Side Components ......... 88 Left-Side Components ..........92 Removing Left-Side Components....... 93 Servicing Left-Side Components ........ 94 Installing Left-Side Components......... 96 Right-Side Components..........99 CC001D Removing Right-Side Components ......
  • Page 83 CC013D CD211A 8. While holding the chain, slide the sprocket and camshaft 5. Loosen the cap screw on the end of the tensioner; out of the cylinder head. then remove the two cap screws securing the ten- sioner adjuster assembly and remove the assembly. ...
  • Page 84 CC017D CC022D C. Cylinder D. Piston  NOTE: Steps 1-12 in the preceding sub-section must precede this procedure. 13. Loosen the clamp securing the coolant hose to the union; then detach the hose. 14. Remove the two nuts securing the cylinder to the crank- case.

  • Page 85: Servicing Top-Side Components

    CC025D CC033D  NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Con- necting Rod Holder. CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result.
  • Page 86 If valves, valve guides, or valve seats require servicing or Water or parts-cleaning solvent must be used in con- replacement, Arctic Cat recommends that the compo- junction with the wet-or-dry sandpaper or damage to nents be taken to a qualified machine shop for servicing.
  • Page 87  NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. CC400D 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. ...
  • Page 88 ATV-1070 ATV-1085B 2. Insert an inside dial indicator into the piston-pin  NOTE: Note the direction of the exhaust side of the bore. The diameter must not exceed specifications. piston (5) for correct ring end gap orientation. Take two measurements to ensure accuracy. 2.
  • Page 89 Cleaning/Inspecting Cylinder Head CAUTION The cylinder head studs must be removed for this pro- cedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the com- bustion chamber or the sealing surface.
  • Page 90 Inspecting Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements.

  • Page 91: Installing Top-Side Components

    CF061A CF083 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.
  • Page 92 C. Cylinder Head D. Valve Cover  NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 6. Place the chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. CC272D 9.
  • Page 93 15. With the cam lobes directed down (toward the pis- ton), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket.  NOTE: Note the position of the alignment marks on the end of the camshaft.
  • Page 94 CD466 CD501 21. Place the C-ring into position in its groove in the cyl-  NOTE: The adjuster shaft will be drawn into the ten- inder head. sioner as the adjuster screw is rotated clockwise. The adjuster shaft tension will be released in step 25. 24.

  • Page 95: Left-Side Components

    CD471 CC003D 26. Loosen the four adjuster screw jam nuts; then loosen 30. In a crisscross pattern starting from the center and the four adjuster screws on the rocker arms in the working outward, tighten the cap screws (from step valve cover.

  • Page 96: Removing Left-Side Components

    7. Using an appropriate side case puller, remove the side cover. Account for a gasket and two alignment Removing Left-Side pins. Components 8. Remove the nut securing the magneto rotor to the crankshaft; then install the magneto rotor puller adapter. A.

  • Page 97: Servicing Left-Side Components

     NOTE: There is an oil passage beneath the driven gear/drive gear assembly. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase. 13.
  • Page 98 FI569 FI576A 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly. FI578 REPLACING STARTER GEAR BEARING FI572 REPLACING STARTER CLUTCH 1. Support the starter clutch gear in a press making sure to support the hub around the entire circumference;...

  • Page 99: Installing Left-Side Components

    FI580 FI595A INSPECTING STATOR COIL/ Installing Left-Side MAGNETO COVER ASSEMBLY Components 1. Inspect the stator coil for burned or discolored wir- ing, broken or missing hold-down clips, or loose cap screws.  NOTE: Plug the oil passage in the crankcase hous- 2.
  • Page 100 CD949 CD139  NOTE: The sharp side of the snap ring should be facing outward. 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing out- ward as noted in removing); then secure with the snap ring.
  • Page 101 PR433A CD954A CD934 CD927A 6. Install the shift cam stopper, spring, and two washers 8. Lubricate the magneto cover gasket with fresh (thick washer closest to the nut); then coat the engine oil; then place it into position on the two threads on the mounting stud with red Loctite #271 alignment pins.

  • Page 102: Right-Side Components

    Right-Side Components  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT  To service any one specific component, only limited dis- GZ253 assembly of components may be necessary.
  • Page 103 CF373A CF632A 7. Remove the cap screws securing the clutch cover. Note the location of the different-lengthed cap screws for installing purposes. Using a rubber mallet, carefully remove the cover. Account for two align- ment pins. CF378 3. Remove the V-belt. 4.
  • Page 104 CF088A A. Oil Pump Driven Gear D. One-Way Clutch 10. Remove the two cap screws securing the gear posi- B. Oil Pump Drive Gear E. Final Drive Carrier Bearing tion switch; then remove the switch. Housing C. Clutch Shoe Assembly CC829B 11.

  • Page 105: Servicing Right-Side Components

    CD987 CD984 CD993 CD895A 13. Using an impact wrench, remove the cap screws 15. Using an impact driver, remove the three torx-head securing the final drive carrier bearing housing (E); screws securing the oil pump; then remove the pump. then remove the housing and account for two align- ment pins.

  • Page 106: Installing Right-Side Components

    Installing Right-Side Components 1. Install the secondary shaft bearing housing making sure the two alignment pins are properly positioned. Tighten the new “patch-lock” cap screws to 28 ft-lb. ATV1014 INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear.
  • Page 107 CD991 PR410A 4. Grease the driven gear pin and insert the oil pump 6. Install the clutch cover alignment pins into the crank- into the case. Tighten the oil pump screws to 8 ft-lb. case, apply oil to the cover gasket, and install the Install the washer and pin;...
  • Page 108 CF085A CF270A 9. Apply grease to the outer edges of the clutch hous- ing; then from inside the clutch cover, install the clutch housing into the cover using a rubber mallet. 10. Place the clutch cover/housing assembly into posi- tion on the crankcase; then secure with the cap screws making sure the different-lengthed cap screws are in their proper location.

  • Page 109: Center Crankcase Components

    Center Crankcase Components  NOTE: This procedure cannot be done with the engine/ transmission in the frame. Complete Removing proce- dures for Top-Side, Left-Side, and Right-Side must pre- cede this procedure.  NOTE: For efficiency, it is preferable to remove and dis- assemble only those components which need to be CF366 addressed and to service only those components.
  • Page 110 DE677A A. Secondary Driven Shaft E. Driveshaft 5. Remove the countershaft assembly (D). Account for Assembly F. Reverse Idler Gear Assembly a washer on each end of the countershaft. B. Crank Balancer Assembly G. Gear Shift Shaft C. Crankshaft H. Shift Shaft with 2 Forks D.

  • Page 111: Servicing Center Crankcase Components

    CAUTION Unless the secondary drive gear, bevel gear, or bear- ings require service, do not remove the secondary drive assembly from the case. If removed, bevel gear back- lash will have to be adjusted requiring re-shimming of the drive bevel gear shaft. 13.
  • Page 112 MT011B MT008B 3. If installing the existing shaft, start with the shims  NOTE: Do not use a new lock nut at this time as this removed during disassembly or if installing a new procedure may have to be repeated. shaft, start with approximately 1.0 mm shims at point (D);...
  • Page 113 MT005A CC290D 5. Acceptable backlash range is 0.127-0.381 mm 2. Maximum diameter must not exceed specifications. (0.005-0.015 in.). Measuring Connecting Rod Correcting Backlash (Small End Deflection)  NOTE: If backlash measurement is within the 1. Place the crankshaft on a set of V blocks and mount a acceptable range, no correction is necessary.
  • Page 114 COUNTERSHAFT H1-003 3. Zero the indicator and rotate the crankshaft slowly. GZ281A CAUTION CAUTION Care should be taken to support the connecting rod When disassembling the countershaft, care must be when rotating the crankshaft. taken to note the direction each major component (dog, 4.
  • Page 115 GZ312 GZ319 3. Remove the reverse driven gear dog. GZ318A 6. Remove the low driven gear. Account for a bearing, GZ313A bushing, and thrust washer. 4. Remove the snap ring securing the reverse driven gear and washer; then remove the washer and gear. GZ316 GZ314 Assembling...
  • Page 116 GZ317A GZ286A GZ318 GZ287 2. Install the low driven gear locking washer; then 4. Install the outer reverse driven washer; then secure install the inner reverse driven gear washer. the reverse driven gear assembly with a snap ring. GZ319B GZ288A GZ320B GZ314 3.

  • Page 117: Assembling Crankcase Half

    GZ313A MT014 2. Apply a liberal amount of engine oil to the crank- shaft bearing. Using a propane torch, heat the bear- ing until the oil begins to smoke; then slide the crankshaft assembly into place. GZ312 6. From the opposite end of the countershaft, install the high/low driven gear dog (A), thrust washer (B), bushing (C), bearing (D), high/low driven gear (E), and spacer washer (F).
  • Page 118 CD832B CC674 7. Place a washer on the end of the gear shift shaft; then  NOTE: It will be necessary to rotate the crank bal- install the shaft assembly making sure the two holes ancer until the counterweight is facing away from the on the end of the shaft are positioned vertically.

  • Page 119: Installing Engine/Transmission

    PR787B 11. Place the oil strainer into position; then secure with the two screws. NOTE: Arctic Cat recommends new gaskets and O- 12. Place the oil strainer cap into position making sure rings be installed whenever servicing the vehicle. silicone sealant is applied; then secure the cap with cap screws.
  • Page 120 HDX156A HDX152A 3. Remove the plugs from the oil cooler lines and 8. Install the CVT cooling ducts on the V-bolt hous- connect to the appropriate fittings. Secure with ing and secure with clamps. Tighten securely. hose clamps and tighten securely. Install an appropriate nylon tie to secure the exhaust duct.
  • Page 121 13. Install the air filter assembly and secure to the frame with four sheet metal screws; then secure the intake boot with the clamp and tighten securely. HDX252A HDX148A 14. Connect the IAT sensor connector to the IAT sen- sor and the crankcase breather tube to the crank- case;...
  • Page 122 HDX158B HDX136A 18. Connect the negative battery cable to the battery. 17. Pour the recommended amount of oil and coolant into the engine and radiator; then loosen the cool- 19. Install the center skid plate, center floorboard, and ant bleed screw to allow trapped air to escape. seat base;...

  • Page 123: Fuel/Lubrication/Cooling

    2. Remove the seat, seat back, and seat base; then dis- connect the battery. Fuel/Lubrication/Cooling 3. Remove the air inlet boot between the air filter and throttle body; then disconnect the MAP sensor con- nector (A), fuel injector connector (B), and ISC con- TROUBLESHOOTING nector (C).

  • Page 124: Gas Tank

    Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. REMOVING 1. Remove the seat, seat back, and seat base; then FI092A remove the floorboard.
  • Page 125 4. Remove four press-nuts securing the gas cap filler panel; then remove the gas cap and panel. Install the gas cap. PR173 PR168 5. Remove the joining cap screw and nut from the rear gas tank hold-down strap; then remove the inside hold-down strap.

  • Page 126: Gas/Vent Hoses

    7. Position the floorboard into the vehicle and secure with the appropriate hardware; then install the seat base, seat back, and seat. Gas/Vent Hoses Replace the gas hose every two years. Damage from aging may not always be visible. Do not bend or obstruct the routing of the vent hoses.

  • Page 127: Liquid Cooling System

    When filling the cooling system, use premixed Arctic Cat Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, open the bleed screw on the thermostat housing to allow air to bleed from the cooling system.

  • Page 128: Thermostat

    5. Remove the two shoulder bolts and nuts securing the radiator to the frame; then disconnect the upper and lower coolant hoses. PR183A 3. Open the high-point bleed screw on the thermostat housing to allow trapped air to escape. Tighten securely after filling.

  • Page 129: Fan

    2. Using the following procedure, inspect the thermostat for proper operation. Water Pump A. Suspend the thermostat in a container filled with water.  NOTE: The water pump is not a serviceable com- B. Heat the water and monitor the temperature with a thermometer.

  • Page 130: Troubleshooting

    INSTALLING 1. Secure the water pump to the engine with the two cap screws tightened to 8 ft-lb. HDX158B NOTE: While the cooling system is being filled, air pockets may develop; therefore, run the engine for five minutes after the initial fill, shut the engine CC786A off, and then fill the cooling system.

  • Page 131: Electrical System

     NOTE: Arctic Cat recommends the use of the CTEK LED(s) are good, that the connections are clean and tight, that the battery is fully charged, and that all appropriate Multi US 800 or the CTEK Multi US 3300 for battery switches are activated.

  • Page 132: Switches

    Connector Charging  NOTE: Arctic Cat recommends the use of the CTEK NOTE: This test procedure is for either the recep- Multi US 800 or the CTEK Multi US 3300 for battery tacles or the connectors.

  • Page 133: Engine Coolant Temperature (Ect) Sensor

    VOLTAGE (Wiring Harness Connector) Engine Coolant Temperature (ECT) 1. Set the meter selector to the DC Voltage position. Sensor 2. Connect the red tester lead to the orange wire; then connect the black tester lead to battery ground. Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen.

  • Page 134: Power Distribution Module (Pdm)

     NOTE: Battery voltage will be indicated from only NOTE: To determine if the fan motor is good, con- nect the red wire from the fan connector to the posi- one side of the fuse holder connector terminal; the tive side of a 12 volt battery; then connect the black other side will show no voltage.

  • Page 135: Efi Sensors/Components

    Secondary Winding AC Voltage NOTE: The battery must be at full charge for 1. Connect the red tester lead to the high tension lead (with the plug cap removed); then connect the black these tests. tester lead to either primary terminal. 1.

  • Page 136: Speed Sensor

    MANIFOLD ABSOLUTE PRESSURE/ INLET AIR TEMPERATURE (MAP/IAT) SENSOR Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen.  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section).

  • Page 137: Rpm Limiter

    RPM Limiter Component data can be retrieved using the CATT II. Uti- lize the Sensor Data screen.  NOTE: The ROV is equipped with an ECM that cuts fuel spray and spark when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire. Warranty Incorrect ECU/ Gear...
  • Page 138 Code Fault Description Fault Condition Possible Cause EPS Fault Recovery Method C1310 Vehicle Speed High Vehicle speed signal received by the Intermittent main harness wires, defective EPS will auto-recover when the vehi- EPS exceeds the maximum speed speed-sensor, or intermittent speed sensor cle speed signal drops below the specification wires.

  • Page 139: Ignition Switch

    Ignition Switch Drive Select Switch To access the ignition switch, dash switches, front acces- sory connectors, and front switched accessory connector, the dash must be unfastened and slid to the rear. Component data can be retrieved using the CATT II. Uti- VOLTAGE lize the Sensor Data screen.

  • Page 140: Reverse Override Switch

    NOTE: If the meter does not show voltages accord- ing to the chart, make sure the front drive actuator is plugged in; then troubleshoot the switch, ignition fuses, battery connections, or wiring harness. Reverse Override Switch VOLTAGE NOTE: To perform the following tests, the ignition switch must be in the ON position and the trans- PR293 mission shifted into reverse gear.

  • Page 141: Stator Coil

    RESISTANCE (AC Generator) Stator Coil CAUTION Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. VOLTAGE (AC Generator - Regulated Output) 1. Set the meter selector to OHMS position. 2. Test between the three yellow wires for a total of 1.

  • Page 142: Starter Relay

    4. Disconnect the two-wire plug from the starter relay; then connect the red tester lead to the green wire and the black tester lead to the black wire. AR607D NOTE: If the meter showed battery voltage but the starter did not operate or operated slowly, PR297A inspect battery voltage (at the battery), starter con- 5.

  • Page 143: Fuel Pump/Fuel Level Sensor

    4. If the pump is not running, disconnect the fuel pump/ sensor connector by reaching under the rear rack Fuel Pump/Fuel Level from behind. Sensor 5. Connect a multimeter to the power supply leads with the red tester lead to the red wire and the black tester lead to the black wire;...

  • Page 144: Regulator/Rectifier

    4. Start the engine to verify proper engine operation; then shut off the engine and install the seat base, seat back, and seat. Regulator/Rectifier The regulator/rectifier is located under the seat next to the battery. Try to verify all other charging system components before the regulator/rectifier is replaced.

  • Page 145: Taillight-Brakelight

    If ignition timing cannot be verified, the rotor may be dam- aged, the key may be sheared, the trigger coil bracket may Taillight-Brakelight be bent or damaged, or the ECM may be faulty. VOLTAGE (Taillight) Tilt Sensor NOTE: Perform this test at the socket end of the taillight-brakelight harness (pigtail).

  • Page 146: Throttle Position Sensor (Tps)

    OUTPUT VOLTAGE NOTE: Needle adapters will be required on the multimeter leads as the following tests are made with the sensor connected. 1. Connect the three-wire plug to the sensor; then remove the right-side mounting screw securing the sensor to the rear frame. CD709 NOTE: When replacing the sensor after testing, make sure the arrow marking is directed up.

  • Page 147: Efi Diagnostic System

      NOTE: If the vehicle is in warranty, removing or NOTE: If the throttle body, ECM, TPS, or ISC are adjusting the TPS will void warranty. If the TPS is replaced, the EFI system must be synchronized. Use tested out of specification, the throttle body must be the following procedure.
  • Page 148 Coolant (COOL) Diagnostic Mode EFI004 NOTE: The gauge can be utilized dynamically EFI 003 (engine running/vehicle moving) or statically Display: Engine coolant temperature as measured by the ECT sensor. (engine/vehicle stopped). DTC: P0116, P0117, P0118, P0119 Examples of Static checks: Battery voltage, fuel gauge/ sensor, and TPS (0% @ closed throttle, 95-100% @ Usage: Monitor coolant temperature to verify the following.
  • Page 149 Tachometer (tACH) Diagnostic TPS (tPS) Diagnostic Mode Mode EFI007 EFI009 Display: % of TPS (0% closed, 95-100% WOT). Display: Engine RPM DTC: P0121, P0122, P0123 DTC: P0336, P0337, P0339 Usage: Verify engine speed signal from the following. Usage: Verify TPS signal and adjust throttle cable. 1.
  • Page 150 Inlet Air Temperature (AIr) Display: System DC voltage. Diagnostic Mode DTC: P0562, P0563, P2531, P2532 Usage: Verify system voltage under following condi- tions. 1. Battery voltage with engine and accessories off (>12.2 VDC for fully charged). 2. Battery voltage with engine running (charging = 13.8 VDC or greater).
  • Page 151 Code Fault Description Possible Cause Fault Recovery Method P0172 O2 Feedback Exceeds Maximum Correc- Excessive fuel rail pressure, MAP or temp sensors out-of-spec Correct condition* tion P0219 Engine Over-Speed Condition Engine speed (RPM) has exceeded the ECM over-speed setpoint/ Reduce engine speed limit P0231 Fuel Pump Relay Circuit Low/SG/Open...

  • Page 152: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug(s) defective 2. Replace plug(s) 3. CKP sensor defective 3. Replace CKP sensor 4. ECM defective 4. Replace ECM Problem: Spark plug fouled with carbon Condition Remedy 1.

  • Page 153: Drive System

    REMOVING Drive System 1. Select LOCK on the drive select switch; then discon- nect the connector on the actuator harness. 2. Using a T-30 torx wrench, remove the mounting cap GENERAL INFORMATION screw from the driveshaft side of the actuator. All gear cases are tagged beneath a cover bolt.

  • Page 154: Front Differential

     NOTE: Make sure to properly align the differential 7. Secure the wiring harness to the frame with a nylon cable tie. lock actuator lever with the hole in the differential lock plunger. Front Differential REMOVING 1. Remove the belly panel; then place the vehicle on jack stands adjusted high enough to allow working from the underside of the vehicle.
  • Page 155 PR264A PR222 7. Disconnect the front drive actuator connector from 10. Support the axle to not allow it to drop or hang. the main harness. CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur. 11.
  • Page 156 PR205A GC015 14. Remove the upper differential mounting cap screw. Account for a lock nut and two washers. CD106 3. Remove the snap rings from the input shaft; then remove the input shaft from the pinion housing. CD016 15. Free the differential assembly from the frame mount- ings;...
  • Page 157 5. Remove the snap ring securing the input shaft bear- ing; then place the pinion housing in a press and remove the bearing. GC012 GC011 GC011 2. Install the input shaft seal making sure it is fully seated in the edge of the housing. AF984 GC014 KX219...
  • Page 158 GC009A GC015 5. Place the pinion housing with new gasket onto the 2. Using a T-40 torx wrench, remove the cap screws differential housing; then secure with existing cap securing the differential cover. Account for and make screws. Tighten to 23 ft-lb. note of the ID tag location for assembling purposes.
  • Page 159 KX175 KX181 5. Remove the left differential bearing flange assembly Disassembling Pinion Gear and account for a shim. Mark the shim as left-side. 1. Remove the internal snap ring securing the pinion bearing in the housing. KX177 WC430 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing.
  • Page 160 CC879 CC884 4. Remove any reusable parts from the gear case hous- 3. Using a propane torch, heat the gear case housing to ing; then discard the housing and lock collar. approximately 200° F; then install the pinion assem- bly. Assembling Pinion Gear 4.
  • Page 161  NOTE: All bearings must be installed in the gear case and the pinion properly installed before pro- ceeding. Backlash  NOTE: Always set backlash prior to any other shim- ming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly.
  • Page 162 2. Zero the dial indicator; then push the ring gear toward the dial indicator and release. End-play should be 0.004-0.008 in. 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness.  NOTE: Once proper backlash and end play are estab- lished, the gear case can be assembled.
  • Page 163 3. Assemble the fork and sliding collar into the cover 6. Install the shift fork shaft w/spring into the housing assembly; then install the left bearing flange/bearing making sure the shaft O-ring is positioned to the assembly and seat firmly into the cover. inside.
  • Page 164 INSTALLING DIFFERENTIAL 1. Place the differential assembly into position in the frame; then install the top mounting cap screw, two washers, and lock nut. Do not tighten at this time. 2. Install the lower differential mounting cap screw, washers, and lock nut. Note the correct location for the washers. CD110 Removing/Installing Axle Seal NOTE: This procedure can be performed on a...

  • Page 165: Drive Axles

    PR193 PR256 8. Secure the lower shock eyelets with cap screws and 12. Install the wheels and tighten in 20 ft-lb increments lock nuts. Tighten to 20 ft-lb. to 40 ft-lb (steel wheel) or 80 ft-lb (aluminum wheel). 13. Remove the vehicle from the support stand. 14.
  • Page 166 PR221 PR729C 5. Remove the cap screw and lock nut securing the REMOVING FRONT DRIVE AXLE knuckle to the upper A-arm. Discard the lock nut.  NOTE: For removing a front drive axel, see Front Differential in this section. CLEANING AND INSPECTING AXLES ...
  • Page 167 CF337 ATV-1048 2. Place the white-striped end of the CV joint into a 3. Apply 80 grams (2/3 of contents) of grease from the vise. pack into the bearing housing.  NOTE: Steps 1-3 can be used to replace the out- board boot.

  • Page 168: Rear Gear Case

    CD027 PR065A 5. Install the wheel. Tighten in 20 ft-lb increments to 40 ft-lb (steel wheel) or 80 ft-lb (aluminum wheel). Rear Gear Case 6. Remove the vehicle from the support stand and release the parking brake. INSTALLING FRONT DRIVE AXLE REMOVING 1.
  • Page 169 RING GEAR /THRUST BUTTON 4. If clearance is not as specified, repeat steps 1 and 2 using thicker shim (clearance too great) or thinner Removing shim (clearance too small) until correct specification is reached. 1. Remove the cap screws securing the gear case cover REAR DRIVE INPUT SHAFT/ to the gear case;...
  • Page 170 GZ184A GZ182A 3. Apply grease to the lips of the oil seal; then install Cleaning and Inspecting the input shaft into the input bearing and housing. 1. Wash all parts in parts cleaning solvent and dry with compressed air. ! WARNING Always wear safety glasses when working with com- pressed air.

  • Page 171: Hub

    REMOVING 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel.  NOTE: Removing or tightening of the hub nuts requires the axles be locked. To lock the rear axle, place the transmission in park. To lock the front axle, turn the ignition switch to ON and select LOCK on the PR254A drive select switch;...

  • Page 172: Hydraulic Brake Caliper

    3. Install the hub assembly onto the axle; then place the transmission in park. ! WARNING Arctic Cat recommends only authorized Arctic Cat ROV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.
  • Page 173 PR235 PR238 5. Remove the caliper holder from the caliper and dis- CAUTION card the O-ring. Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the vehicle and do not reuse brake fluid.  NOTE: Whenever brake components are removed, disassembled, or repaired where brake fluid is exposed to air, drain all fluid and replace with new DOT 4 brake fluid from an unopened container.
  • Page 174 PR715 PR717A ! WARNING 2. Press the piston into the caliper housing using hand pressure only. Completely seat the piston; then wipe Make sure to hold the towel firmly in place or the piston off any excessive brake fluid. could be ejected from the housing causing injury. 7.

  • Page 175: Master Cylinder Assembly

    4. Install the caliper onto the caliper holder making sure 7. Place a new crush washer on each side of the brake hose the caliper and holder are correctly oriented. fitting and install it on the caliper. Tighten to 20 ft-lb. NOTE: It is very important to apply silicone 8.

  • Page 176: Universal Joints

    3. Remove the cap screws securing the driveshaft flange to the output flange; then remove the drive- shaft. PR336 3. Remove the oil bolt securing the banjo-fittings to the master cylinder; then remove the master cylinder. Discard the three crush washers. HDX157 4.
  • Page 177 PR367B PR368 2. Check that yoke legs are parallel. 2. Secure U-Joint Separator Tool in a vise; then place the yoke, joint, and bearing cup into position and press the cup into the yoke. PR367A 3. Check splines and flanges for excessive wear, thread damage, or warpage.

  • Page 178: Troubleshooting Drive System

    Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shaft serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1. Secondary drive - driven gear teeth broken 1.

  • Page 179: Suspension

    3. Using a suitable spring compression stand, compress the shock absorber spring, remove the retainer, and Suspension remove the spring. ! WARNING The following suspension system components should be Shock absorber springs are under high compression inspected periodically to ensure proper operation. loads.
  • Page 180 2. Remove the upper and lower mounting cap screws 4. Remove the air chamber from the bottom of the and lock nuts. Discard the lock nuts. shock body. 3. Using a suitable spring compressor, compress the spring and retainer ring from the lower shock body. 4.
  • Page 181 11. Remove the shock rod/piston assembly from the shock body. FS147 8. Using a 5/64-in. Allen-wrench, remove the set screw from the bearing cap. FS151 12. Drain the oil from the shock body into a suitable con- tainer. 13. Using an appropriate floating piston removal tool, remove the floating piston.
  • Page 182 FS154 FS157 2. Carefully install the floating piston into the shock 5. Lubricate the O-ring on the underside of the end cap body until it is below the threads. with shock oil. FS155 FS158 3. Using an appropriate location tool, install the float- 6.
  • Page 183 8. Using Spanner Wrench, tighten the bearing cap. 10. Charge the shock with nitrogen to 200 psi. FS161 FS164 11. Using a 3/16-in. Allen-wrench, tighten the  NOTE: When tightening the bearing cap, note air nitrogen bladder. and excess oil being bled from the hole in the cap. FS165 FS150A 12.
  • Page 184 18. Thread the air chamber into the end cap until hand- tight. FS167 15. Lubricate the seal on the air chamber with Fox Float Fluid. FS171  NOTE: Prior to installing the air chamber, make sure the end cap O-ring is properly positioned in the chamber.

  • Page 185: Front A-Arms

    21. Install the valve cap. CD007 5. Remove the hub assembly. FS174 22. Install the spring using an appropriate spring com- 6. Remove the cotter pin and slotted nut securing the tie pressor and secure with the retaining ring. rod end to the knuckle; then remove the tie rod end from the knuckle.
  • Page 186 AF610D AF616D 11. Remove the snap ring from the ball joint; then remove 2. Install the A-arm assemblies into the frame mounts the ball joint from the A-arm. and secure with the cap screws. Only finger-tighten at this time. AF616D AF610D CLEANING AND INSPECTING 3.

  • Page 187: Rear A-Arms

    AF628D PR377B 7. Install the tie rod end and secure with the nut (coated 11. Secure the hub nut (from step 9) to the shaft/axle. with red Loctite #271). Tighten to 30 ft-lb; then install Tighten to 200 ft-lb. a new cotter pin and spread the pin to secure the nut. 12.
  • Page 188 5. Remove the cap screws and lock nut securing the 3. Tighten the hardware securing the A-arms to the shock absorber to the frame and lower A-arm; then frame mounts (from step 1) to 33 ft-lb. remove the shock absorber. 4.

  • Page 189: Wheels And Tires

    ! WARNING 2. Clean the tires with soap and water. Use only Arctic Cat approved tires when replacing tires. 3. Inspect each wheel for cracks, dents, or bends. Failure to do so could result in unstable vehicle opera- tion.

  • Page 190: Troubleshooting

    Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring preload incorrect 1. Adjust preload 2. Spring(s) weak 2. Replace spring(s) 3. Shock absorber damaged 3. Replace shock absorber 4. Rear shock absorbers too soft 4. Check and adjust air pressure in shocks Problem: Suspension too stiff Condition Remedy...
  • Page 191 NOTES...
  • Page 192 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2260-410...

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